Modern Electro/Thermochemical Advances in Light Metals Systems

Manufacturing Efficiency

Release Date:
Project Count:

Program Description:

The projects that comprise ARPA-E's METALS program, short for "Modern Electro/Thermochemical Advances in Light Metal Systems," aim to find cost-effective and energy-efficient manufacturing techniques to process and recycle metals for lightweight vehicles and aircraft. Processing light metals such as aluminum, titanium, and magnesium more efficiently would enable competition with incumbent structural metals like steel to manufacture vehicles and aircraft that meet demanding fuel efficiency standards without compromising performance or safety.

Innovation Need:

Primary production and recycling of light metals such as aluminum, magnesium, and titanium is energy intensive and expensive while resulting in significant carbon dioxide (CO2) emissions. Several METALS projects focus on transforming the domestic processing of these metals, utilizing integrated system approaches that allow for one or more of the following operational characteristics: variable energy inputs (including renewable energy), high temperature heat recovery, high temperature thermal storage, and use of domestically abundant ores. Other METALS projects focus on sorting and recycling light metals, an inefficient process that is presently performed by hand. Automating light metal scrap sorting techniques so it can be integrated with a high efficiency system would transform light metal recycling. Developing advanced technologies for manufacturing and recycling light metals more efficiently would enable widespread use of light metals in vehicles and aircraft, substantially reducing fuel consumption and CO2 emissions from the transportation sector.

Potential Impact:

If successful, the development of advanced technologies to manufacture and recycle light metals cost effectively will make lightweight vehicles and aircraft more affordable while consuming substantially less energy.


Light-weighting vehicles to improve fuel efficiency could reduce U.S. dependence on foreign fossil fuel resources used to power vehicles and aircraft.


Utilizing light metals to manufacture vehicles and aircraft decreases their weight, reducing overall fuel consumption and resulting CO2 emissions.


Reducing light metal processing costs compared to incumbent structural metals such as steel enables the cost-effective development and operation of lightweight vehicles and aircraft.


Program Director:
Multiple Program Directors manage this program. For specific PD information please refer to the project slick sheet.
Press and General Inquiries Email:

Project Listing

• Alcoa - Aluminum Electrolytic Cell with Heat Recovery
• BlazeTech - Specialized Imaging System for Light Metal Sorting
• Case Western Reserve University - Segmented Cell for Electrowinning Titanium
• Energy Research Company (ERCo) - Integrated Minimill to Produce Aluminum from Scrap
• Gas Technology Institute (GTI) - Membrane Extraction for Aluminum Production
• iMetalx Group - Scaling up Titanium Production
• INFINIUM - Aluminum Production Using Zirconia Solid Electrolyte
• Materials & Electrochemical Research (MER) - Advanced Electrowinning of Titanium
• Pacific Northwest National Laboratory (PNNL) - Extracting Magnesium from Seawater
• Palo Alto Research Center (PARC) - Electrochemical Probe for Rapid Scrap Metal Sorting
• Phinix - Electrochemical Magnesium Extraction from Scrap
• Research Triangle Institute (RTI) - High-Temperature Thermal Storage for Light Metal Production
• SRI International - Direct Production of Titanium Powder
• Titanium Metals Corporation (TIMET) - Electrochemical Cell for Advanced Titanium Production
• UHV Technologies - X-Ray Diagnostics for Scrap Metal Sorting
• University of Colorado, Boulder (CU-Boulder) - Solar/Electric Powered Magnesium Production
• University of Utah - Direct Titanium Production from Titanium Slag
• University of Utah - Electromagnetic Light Metal Sorting
• Valparaiso University - Solar/Electrolytic Production of Magnesium from Ore